478915 Volvo.Penta Cylinder

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
If necessary, remove the bracket for the Clean Emission Module (CEM). Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure.
If necessary, remove the air cleaner bracket. Refer to Disassembly and Assembly, "Air Cleaner- Remove and Install" for the correct procedure.
Illustration 1 g03361445
Illustration 2 g03361447
Loosen hose clamp (2) for hose assembly (3). Remove the hose assembly from check valve (1).
Loosen hose clamp (4) (not shown) for hose assembly (5).
Remove hose assembly (5) from the connection on the inlet manifold.
Position hose assembly (3) and hose assembly (5) away for valve mechanism cover (6).
Disconnect harness assembly (9) from inlet manifold temperature sensor (8).
Disconnect the inlet hose assembly from connection (7) on the inlet manifold.
Illustration 3 g03361446
Cut cable strap (15), cable strap (13), and cable straps (18) from harness assembly (12). Position the harness assembly away from valve mechanism cover (6).
Remove bolts (10) from bracket assembly (11). Position the bracket assembly away from valve mechanism cover (6).
Remove nuts (19) from valve mechanism cover (6). Note: Loosen the nuts evenly in order to avoid distortion of the valve mechanism cover.
Remove bolts (14) (not shown) from valve mechanism cover (6).
Remove sealing washers (20) (not shown) from the studs.
Remove valve mechanism cover (6) from valve mechanism base (16).
Remove gasket (17) (not shown) from valve mechanism cover (6). Installation Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 4 g03361446
Illustration 5 g03361447
Ensure that valve mechanism cover (6) is clean and free from damage. Clean the gasket surface of valve mechanism base (16).
Install a new gasket (17) (not shown) to valve mechanism cover (6). Ensure that the gasket is correctly seated into the recess of the valve mechanism cover.
Position valve mechanism cover (6) onto valve mechanism base (16).
Install new sealing washers (20) (not shown) onto the studs.
Install nuts (19) finger tight.
Install bolts (14) (not shown) to the valve mechanism cover.
Tighten evenly nuts (19) to a torque of 14 N m (124 lb in). Note: Tighten the nuts evenly in order to avoid distortion of the valve mechanism cover.
Tighten bolts (14) to a torque of 10 N m (89 lb in).
Repeat Step 7 in order to ensure nuts (19) achieve the correct torque values.
Repeat Step 12 in order to ensure bolts (14) achieve the correct torque values.
Position bracket assembly (11) onto valve mechanism cover (6). Install bolts (10) to the bracket assembly.
Tighten bolts (10) to a torque of 10 N m (89 lb in).
Position harness assembly (12) onto valve mechanism cover (6). Ensure that the harness assembly is correctly positioned onto the valve mechanism cover and the brackets.
Install new cable strap (15), cable strap (13), and cable straps (18) to harness assembly (12). Note: Ensure that the cable straps meet the Original Manufactures Equipment (OEM) specification.
Connect harness assembly (9) to inlet manifold temperature sensor (8).
Connect the inlet hose assembly to connection (7) on the inlet manifold. Tighten the hose clamp securely.
Illustration 6 g03361445
Position hose assembly (3) and hose assembly (5) onto valve mechanism cover (6).
Connect hose assembly (5) to the connection on the inlet manifold. Ensure that the hose clamp is correctly orientated.
Securely tighten hose clamp (4) (not shown) for hose assembly (5).
Connect hose assembly (3) to check valve (1). Ensure that the hose clamp is correctly orientated.
Securely tighten hose clamp (2) for hose assembly (3).
Connect harness assembly (7) to harness assembly (9).
If necessary, install the bracket for the Clean Emission Module (CEM). Refer to Disassembly and Assembly, "Support and Mounting (CEM) - Remove and Install" for the correct procedure.
If necessary, install the air cleaner bracket. Refer to Disassembly and Assembly, "Air Cleaner- Remove and Install" for the correct procedure.